Air textured yarn (aty) and manufacturing method thereof

ABSTRACT

An air textured yarn (ATY) is disclosed. The ATY includes a first filament having a first cross section, and a second filament disposed adjacent to the first filament having a second cross section, wherein the first cross section has a substantially circular shape and has a degree of modification (M ratio) less than or substantially equal to 1.3, the second cross section has a polygonal shape including 3 to 6 lobes, and a difference between a length of the first filament and a length of the second filament is less than or substantially equal to 4%. Further, a method of manufacturing the ATY is also disclosed.

This application claims priority of U.S. provisional application Ser.No. 63/068,621 filed on 21 Aug. 2020, which is incorporated by referencein its entirety.

TECHNICAL FIELD

The present disclosure relates to an air textured yarn (ATY) multi-lobedfiber, and particularly relates to an ATY having small, dense anduniform loops. Further, the present disclosure relates to a fabric madeof such ATY. Further, the present disclosure relates to a method ofmanufacturing such ATY.

DISCUSSION OF THE BACKGROUND

Air textured yarn (ATY) includes polymeric filaments interlacing witheach other to form crimps and loops that interlock with each other andlock the polymeric filaments together. Such interlacing and interlockingare caused by an air texturizing process. The air texturizing process isa mechanical method of producing the ATY with crimps and loops byblowing an air or liquid toward the polymeric filaments.

Dimensions of crimps and loops in the polymeric filaments wouldessentially affect quality of the ATY as well as a feeling offered by afabric made of such ATY. Conventional ATY is formed by two filamentswith large length difference, and thus has large loops and long crimps,which causes the conventional ATY snag easily. Furthermore, theconventional ATY has loops of lesser density and thus has less of afluffy feeling. In addition, a fabric made of such conventional ATYwould have an undesirable see-through effect.

Accordingly, there is a continuous need to improve a configuration andmanufacturing method of the ATY.

This Discussion of the Background section is provided for backgroundinformation only. The statements in this Discussion of the Backgroundare not an admission that the subject matter disclosed in this sectionconstitutes prior art to the present disclosure, and no part of thisDiscussion of the Background section may be used as an admission thatany part of this application, including this Discussion of theBackground section, constitutes prior art to the present disclosure.

SUMMARY

One aspect of the present disclosure provides an air textured yarn(ATY). The ATY includes a first filament having a first cross section;and a second filament disposed adjacent to the first filament and havinga second cross section. The first cross section has a substantiallycircular shape and has a degree of modification (M ratio) less than orsubstantially equal to 1.3, the second cross section different from thefirst cross section has a polygonal shape including 3 to 6 lobes, and adifference between a length of the first filament and a length of thesecond filament is less than or substantially equal to 4%.

In some embodiments, the length of the first filament is substantiallyequal to the length of the second filament.

In some embodiments, the second cross section has an M ratio greaterthan 1.5.

In some embodiments, the M ratio of the second cross section is in arange of about 1.6 to about 3.

In some embodiments, the second cross section has the polygonal shapeincluding 5 or 6 lobes.

In some embodiments, the ATY further includes a third filament disposedadjacent to the first filament and the second filament and having athird cross section, wherein the third cross section is different fromthe first cross section of the first filament and the second crosssection of the second filament.

In some embodiments, the ATY further includes a loop formed by the firstfilament or the second filament, wherein a height of the loop is lessthan 480 μm.

One aspect of the present disclosure provides a fabric comprising anATY. The ATY includes a first filament having a first cross section; anda second filament disposed adjacent to the first filament and having asecond cross section, wherein the first cross section has asubstantially circular shape and has an M ratio less than 1.3, thesecond cross section different from the first cross section has apolygonal shape including 3 to 6 lobes, and a difference between alength of the first filament and a length of the second filament is lessthan or substantially equal to 4%.

One aspect of the present disclosure provides a method of manufacturingan ATY. The method includes extruding a first filament and a secondfilament from a yarn magazine; feeding the first filament into a nozzleunit by a first feeding member of a feeding unit at a first feedingspeed; feeding the second filament into the nozzle unit by a secondfeeding member of the feeding unit at a second feeding speed; blowingthe first filament and the second filament by a flow in the nozzle unitto form the ATY including the first filament and the second filament;pulling the ATY out from the nozzle unit by a delivery unit; and takingup the ATY from the delivery unit by a take up unit, wherein adifference between the first feeding speed and the second feeding speedis less than or equal to 4%, a first cross section of the first filamentand a second cross section of the second filament have differentcross-sectional shapes, the first cross section of the first filamenthas a substantially circular shape and has a degree of modification (Mratio) less than or substantially equal to 1.3, and the second crosssection of the second filament has a polygonal shape including 5 or 6lobes and has an M ratio substantially greater than 1.5.

In some embodiments, the first feeding speed is substantially equal tothe second feeding speed.

The method further includes feeding a polymeric material into aspinneret; forming a first filament and a second filament from thepolymeric material; outputting the first filament and the secondfilament from the spinneret; combining the first filament and the secondfilament to form a yarn; and conveying the yarn including the firstfilament and the second filament to the yarn magazine.

The method further includes feeding a polymeric material into a firstspinneret and a second spinneret; forming a first filament and a secondfilament from the polymeric material; outputting the first filament fromthe first spinneret and the second filament from the second spinneret;combining the first filament and the second filament to form a yarn; andconveying the yarn including the first filament and the second filamentto the yarn magazine.

The present disclosure provides an ATY having small, dense and uniformloops. The ATY comprises a first filament having a substantiallycircular cross section and an M ratio less than or substantially equalto 1.3, and a second filament having a second cross section differentfrom the first cross section. The second cross section has a polygonalcross section including 3 to 6 lobes. The first filament and the secondfilament are fed into a nozzle unit at a same or approximately samefeeding speed, and then texturized by the nozzle unit. The first andsecond filaments are blown by a compressed air, gas or liquid fluidsupplied from the nozzle unit in order to form loops protruding from theATY.

As a result, a yarn including the first filament and the second filamentis texturized by air, gas or liquid fluid to become the ATY. Since thefirst and second filaments have different cross-sectional profiles withdifferent aerodynamic effects and are fed into the nozzle unit at a sameor approximately same speed, loops having desired dimension, density anddistribution can be produced.

The ATY with small, dense and uniform loops can offer a fluffy,comfortable or cotton-like feeling. Furthermore, since the loopsprotruding from the ATY are small in size, snagging can be reduced. Inaddition, a fabric, garment or clothing made of such ATY has a lowsee-through effect.

The foregoing has outlined rather broadly the features and technicaladvantages of the present disclosure in order that the detaileddescription of the disclosure that follows may be better understood.Additional features and advantages of the disclosure will be describedhereinafter, and form the subject of the claims of the disclosure. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures or processes for carrying outthe same purposes as those of the present disclosure. It should also berealized by those skilled in the art that such equivalent constructionsdo not depart from the spirit and scope of the disclosure as set forthin the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present disclosure may be derivedby referring to the detailed description and claims when considered inconnection with the Figures, where like reference numbers refer tosimilar elements throughout the Figures, and:

FIG. 1 is a schematic side view of an air texturing machine according toone embodiment of the present disclosure;

FIG. 2 is a flowchart illustrating a method of manufacturing an airtextured yarn (ATY) according to various aspects of one or moreembodiments of the present disclosure;

FIG. 3 is a flowchart illustrating another method of manufacturing anair textured yarn (ATY) according to various aspects of one or moreembodiments of the present disclosure;

FIG. 4 is a microscopic image showing a cross-sectional view of an airtextured yarn (ATY) according to one embodiment of the presentdisclosure;

FIG. 5 is a schematic cross-sectional view of a filament having atri-lobe shape according to one embodiment of the present disclosure;

FIG. 6 is a schematic cross-sectional view of a filament having acrisscross shape according to one embodiment of the present disclosure;

FIG. 7 is a schematic cross-sectional view of a filament having apentagram shape according to one embodiment of the present disclosure;

FIG. 8 is a schematic cross-sectional view of a filament having ahexagram shape according to one embodiment of the present disclosure;

FIGS. 9 to 11 are schematic cross-sectional views of filaments having adegree of modification (M ratio) less than or substantially equal to1.3;

FIG. 12 shows schematic side views of an air textured yarn (ATY)according to one embodiment of the present disclosure and a comparativeexample yarn; and

FIG. 13 shows schematic top views of a fabric made of the air texturedyarn (ATY) according to one embodiment of the present disclosure and acomparative example fabric.

DETAILED DESCRIPTION

The following description of the disclosure accompanies drawings, whichare incorporated in and constitute a multi-lobed fiber, a spinneretassembly and a method for manufacturing a multi-lobed fiber of thisspecification, and illustrate embodiments of the disclosure, but thedisclosure is not limited to the embodiments. In addition, the followingembodiments can be properly integrated to complete another embodiment.

References to “one embodiment,” “an embodiment,” “exemplary embodiment,”“some embodiments,” “other embodiments,” “another embodiment,” etc.indicate that the embodiment(s) of the disclosure so described mayinclude a particular feature, structure, or characteristic, but notevery embodiment necessarily includes the particular feature, structure,or characteristic. Further, repeated use of the phrase “in theembodiment” does not necessarily refer to the same embodiment, althoughit may.

As used herein, the terms “approximately,” “substantially,”“substantial” and “about” are used to describe and account for smallvariations. For example, when used in conjunction with a numericalvalue, the terms can refer to a range of variation less than or equal to±4% of said numerical value, such as less than or equal to ±4%, lessthan or equal to ±3%, less than or equal to ±2%, less than or equal to±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or lessthan or equal to ±0.05%. For example, two numerical values can be deemedto be “approximately,” “substantially” or “about” the same if adifference between the values is less than or equal to ±4% of an averageof the values, such as less than or equal to ±4%, less than or equal to±3%, less than or equal to ±2%, less than or equal to ±1%, less than orequal to ±0.5%, less than or equal to ±0.1%, or less than or equal to±0.05%.

In order to make the present disclosure completely comprehensible,detailed steps and structures are provided in the following description.Obviously, implementation of the present disclosure does not limitspecial details known by persons skilled in the art. In addition, knownstructures and steps are not described in detail, so as not to limit thepresent disclosure unnecessarily. Preferred embodiments of the presentdisclosure will be described below in detail. However, in addition tothe detailed description, the present disclosure may also be widelyimplemented in other embodiments. The scope of the present disclosure isnot limited to the detailed description, and is defined by the claims.

FIG. 1 is a schematic side view of an air texturing machine 100according to one embodiment of the present disclosure. In someembodiments, the air texturing machine 100 is configured to manufacturean air texturized yarn (ATY) 105. In some embodiments, the air texturingmachine 100 is configured to implement an air texturing process or amethod of manufacturing the ATY 105. In some embodiments, the airtexturing machine 100 includes a yarn magazine 101, a feeding unit 102,a nozzle unit 103, a delivery unit 104 and a take up unit 106.

In some embodiments, the yarn magazine 101 is configured to draw outfilaments. In some embodiments, the filaments are formed from apolymeric material such as polyester, nylon, polypropylene or the like.In some embodiments, the yarn magazine 101 includes a first extrudingmember 101 a and a second extruding member 101 b. In some embodiments, afirst filament 105 a is extruded from the first extruding member 101 a,and a second filament 105 b is extruded from the second extruding member101 b.

In some embodiments, the first filament 105 a and the second filament105 b can have same or different configurations. In some embodiments,the first filament 105 a and the second filament 105 b have differentcross-sectional shapes. In some embodiments, the first filament 105 ahas a substantially circular cross section. In some embodiments, thesecond filament 105 b has a polygonal cross section including 3 to 6lobes.

Although only two filaments 105 a and 105 b are involved in thisembodiment as shown in FIG. 1, it can be understood that a number of thefilaments is adjustable as desired. In other words, more than onefilament can be extruded from the yarn magazine 101, and more than onefilament can be drawn out from the yarn magazine 101 and fed into thenozzle unit 103, such that the ATY 105 including more than one filamentcan ultimately be formed.

Further, it can be understood that the ATY 105 can include more than onefilament, and at least one of the filaments has a cross sectiondifferent from those of other filaments. In some embodiments, the ATY105 includes three filaments having cross sections different from eachother. For example, three filaments can include a filament having asubstantially circular cross section, a filament having a polygonalcross section including 3 or 4 lobes, and a filament having a polygonalcross section including 5 or 6 lobes.

In some embodiments, the feeding unit 102 is disposed adjacent to theyarn magazine 101. In some embodiments, the first filament 105 a and thesecond filament 105 b are conveyed to the feeding unit 102. In someembodiments, the feeding unit 102 includes a first feeding member 102 afor feeding the first filament 105 a into the nozzle unit 103, and asecond feeding member 102 b for feeding the second filament 105 b intothe nozzle unit 103. In some embodiments, the first feeding member 102 aand the second feeding member 102 b are feeding rollers.

In some embodiments, the first filament 105 a is fed into the nozzleunit 103 at a first feeding speed, and the second filament 105 b is fedinto the nozzle unit 103 at a second feeding speed. In some embodiments,a difference between the first feeding speed and the second feedingspeed is less than or substantially equal to 4%. In some embodiments,the first feeding speed and the second feeding speed are the same orapproximately the same. In other words, the first feeding speed issubstantially equal to the second feeding speed. The substantially equalfirst feeding speed and second feeding speed thus results in thesubstantially equal lengths of the first filament 105 a and the secondfilament 105 b. Since the length difference between first filament 105 aand second filament 105 b limits the loops length at ATY 105, the ATY105 will not be easily snagged due to their substantially equal lengths.In some embodiments, a difference between a length of the first filament105 a and a length of the second filament 105 b is less than orsubstantially equal to 4%. In some embodiments, the length of the firstfilament 105 a is substantially equal to the length of the secondfilament 105 b. The first filament 105 a and the second filament 105 bhave substantially the same length, but different cross-sectionalprofiles with different aerodynamic effects, and thus the ATY 105 formedby the first filament 105 a and the second filament 105 b have small,dense and uniform loops, which thus generates desired properties such asfluffy feeling and non-see-through effect.

In some embodiments, the first filament 105 a and the second filament105 b are fed into the nozzle unit 103 by the feeding unit 102. In someembodiments, the nozzle unit 103 is configured to texturize thefilaments 105 a and 105 b passing through the nozzle unit 103. In someembodiments, the first filament 105 a and the second filament 105 b areblown by a flow such as air, gas or liquid fluid supplied from thenozzle unit 103, such that the first filament 105 a and the secondfilament 105 b are mixed and texturized to become the ATY 105. In someembodiments, the air, gas or liquid fluid supplied from the nozzle unit103 flows toward a predetermined direction.

In some embodiments, the ATY 105 is a combination of the first filament105 a and the second filament 105 b. In some embodiments, the ATY 105includes a plurality of the first filaments 105 a and a plurality of thesecond filaments 105 b.

As a result, loops protruding from the ATY 105 are formed. Since thefirst filament 105 a and the second filament 105 b are fed into thenozzle unit 103 at the same speed or approximately the same speed, theATY 105 with small, dense and uniform loops can be produced.

In some embodiments, the ATY 105 is pulled out from the nozzle unit 103by the delivery unit 104. In some embodiments, the delivery unit 104 isan output roller. In some embodiments, the ATY 105 is outputted from thenozzle unit 103 by the delivery unit 104 at an output speed. In someembodiments, the output speed is less than the first feeding speed orthe second feeding speed. In some embodiments, a difference between thefirst feeding speed and the output speed ranges of about 6% to about16%. In some embodiments, a difference between the first feeding speedand the output speed ranges of about 7% to about 14%. In someembodiments, a difference between the first feeding speed and the outputspeed ranges of about 8% to about 13%. In some embodiments, a differencebetween the second feeding speed and the output speed ranges of about 6%to about 16%. In some embodiments, a difference between the secondfeeding speed and the output speed ranges of about 7% to about 15%. Insome embodiments, a difference between the second feeding speed and theoutput speed ranges of about 8% to about 14%. In some embodiments, aninput speed of the feeding unit 102 is substantially same as the firstfeeding speed or the second feeding speed.

In some embodiments, the ATY 105 is wound by the take up unit 106. Insome embodiments, the take up unit 106 is a take up roller for windingthe ATY 105. The ATY 105 is finally wound around the take up unit 106.

In the present disclosure, a method of manufacturing an ATY 105 isdisclosed. In some embodiments, the ATY 105 is manufactured byimplementing a method S100. FIG. 2 is an embodiment of the method S100implemented by the air texturizing machine 100 as described above orillustrated in FIG. 1. The method S100 includes a number of operationsand the description and illustration are not deemed as a limitation asthe sequence of the operations. The method S100 may, but is not limitedto, include a number of operations (S101, S102, S103, S104, S105 andS106). In some embodiments, the method S100 is implemented inautomation.

In step S101, a first filament 105 a and a second filament 105 b areextruded from a yarn magazine 101. In some embodiments, the firstfilament 105 a is extruded from the first extruding member 101 a, andthe second filament 105 b is extruded from the second extruding member101 b. In some embodiments, after the first filament 105 a and thesecond filament 105 b are extruded from the yarn magazine 101, the firstfilament 105 a and the second filament 105 b are conveyed to the feedingunit 102. In some embodiments, the first filament 105 a and the secondfilament 105 b are conveyed to a first feeding member 102 a and a secondfeeding member 102 b, respectively.

In step S102, the first filament 105 a is fed into a nozzle unit 103 bythe first feeding member 102 a of the feeding unit 102 at a firstfeeding speed. In a step S103, the second filament 105 b is fed into thenozzle unit 103 by the second feeding member 102 b of the feeding unit102 at a second feeding speed. In some embodiments, the step S102 andthe step S103 are implemented separately or simultaneously. In someembodiments, the first feeding speed and the second feeding speed arethe same or approximately the same. In some embodiments, the differencebetween the first feeding speed and the second feeding speed is lessthan or substantially equal to 4%. Since the first filament 105 a andthe second filament 105 b are fed into the nozzle unit 103 at a same orapproximately same speed, the ATY 105 having loops with desireddimension, density and distribution can be produced.

In step S104, the first filament 105 a and the second filament 105 b areblown by a flow in the nozzle unit 103 to form the ATY 105. In someembodiments, the nozzle unit 103 supplies air, gas or liquid to blow thefirst filament 105 a and the second filament 105 b when the firstfilament 105 a and the second filament 105 b pass through the nozzleunit 103. In some embodiments, the blowing includes mixing andtexturizing the first filament 105 a and the second filament 105 b.

Since the first filament 105 a and the second filament 105 b havedifferent cross-sectional shapes, an aerodynamic effect on the firstfilament 105 a is different from an aerodynamic effect on the secondfilament 105 b. In some embodiments, the first filament 105 a having asubstantially circular cross section and an M ratio substantially equalto or less than 1.3 has a smaller effective contact surface than thesecond filament 105 b having a polygonal cross section including 3 to 6lobes, and therefore, the first filament 105 a and the second filament105 b incur different degrees of turbulence. Further, loops protrudingfrom the ATY 105 are formed. Since the first filament 105 a and thesecond filament 105 b are fed into the nozzle unit 103 at the same speedor approximately the same speed, the ATY 105 with small, dense anduniform crimps can be produced.

In step S105, the ATY 105 is pulled out from the nozzle unit 103 by adelivery unit 104. In some embodiments, the ATY 105 is a combination ofthe first filament 105 a and the second filament 105 b. In someembodiments, the ATY 105 is pulled out from the nozzle unit 103 at anoutput speed. In some embodiments, a difference between the output speedand the first feeding speed is substantially less than or equal to 16%.In some embodiments, a difference between the output speed and thesecond feeding speed is substantially less than or equal to 16%.

In step S106, the ATY 105 is taken up from the delivery unit 104 by atake up unit 106. In some embodiments, the ATY 105 is finally woundaround the take up unit 106.

Although FIGS. 1 and 2 describe that the first filament 105 a and thesecond filament 105 b are combined prior to being fed into the nozzleunit 103, it can be understood that the first filament 105 a and thesecond filament 105 b can be combined before entering the air texturingmachine 100, or even several (e.g., more than three) filaments can becombined before entering the air texturing machine 100. For example, thefirst filament 105 a and the second filament 105 b can be combined by amelt spinning process prior to the air texturing process implemented bythe air texturing machine 100.

In the present disclosure, another method of manufacturing the ATY 105is disclosed. In some embodiments, the ATY 105 is manufactured byimplementing another method S200. FIG. 3 is an embodiment of the methodS200 of performing the melt spinning process by a melt spinning machineand the air texturing process by the air texturizing machine 100 asdescribed above or illustrated in FIG. 1. The method S200 includes anumber of operations and the description and illustration are not deemedas a limitation to the sequence of the operations. The method S200 may,but is not limited to, include a number of operations (S201, S202, S203,S204, S205, S206, S207, S208, S209 and S210). In some embodiments, themethod S200 is implemented in automation.

In step S201, polymeric material is fed into a spinneret. In someembodiments, the polymeric material is polymer melt, polymer solution orthe like. In some embodiments, the polymeric material includespolyester, nylon, polypropylene or the like. In some embodiments, thespinneret is configured to extrude the polymeric material to becomefiber or filament. In some embodiments, the spinneret is in aconfiguration as generally known in the art. In some embodiments, thepolymeric material is fed into several spinnerets separated from eachother.

In step S202, a first filament 105 a and a second filament 105 b areformed from the polymeric material. In some embodiments, the firstfilament 105 a and the second filament 105 b are formed by one or morespinnerets. In some embodiments, the first filament 105 a having a firstcross section and the second filament 105 b having a second crosssection substantially different from the first cross section are formedby one or more spinnerets. In some embodiments, the first cross sectionof the first filament 105 a has a circular shape, and the second crosssection of the second filament 105 b is a pentagram or hexagram. In someembodiments, the second cross section of the second filament 105 b hasan M ratio substantially greater than 1.5.

In step S203, the first filament 105 a and the second filament 105 b areoutputted from one or more spinnerets. In some embodiments, the firstfilament 105 a and the second filament 105 b are outputted from thespinnerets respectively. In some embodiments, the first filament 105 aand the second filament 105 b are outputted from the same spinneret. Insome embodiments, the first filament 105 a and the second filament 105 bare outputted from separate respective spinnerets.

In step S204, the first filament 105 a and the second filament 105 b arecombined to form a yarn. In some embodiments, the first filament 105 aand the second filament 105 b are combined together to become the yarnincluding the first filament 105 a and the second filament 105 b. Insome embodiments, the yarn including the first filament 105 a and thesecond filament 105 b is drawn and heat-set based on the melt spinningprocess generally known in the art, and the yarn is then wound up on acone. Subsequently, the cone is conveyed to a yarn magazine 101 of theair texturing machine 100 for the air texturing process as describedabove or illustrated in FIG. 1.

In step S205, the yarn including the first filament 105 a and the secondfilament 105 b is conveyed to the yarn magazine 101. In step 206, theyarn including the first filament 105 a and the second filament 105 b isextruded from the yarn magazine 101. In some embodiments, after the yarnis extruded from the yarn magazine 101, the yarn is conveyed to afeeding unit 102.

In step S207, the yarn is fed into a nozzle unit 103 by the feeding unit102 at an input speed. In step S208, the yarn is blown by the nozzleunit to form the ATY 105 including the first filament 105 a and thesecond filament 105 b. In some embodiments, the step S208 is similar tothe step S104 described above.

In step S209, the ATY 105 is pulled out from the nozzle unit 103 by adelivery unit 104 at an output speed. In some embodiments, a differencebetween the input speed and the output speed ranges of about 6% to 16%.In some embodiments, the step S209 is similar to the step S105 describedabove. In step S210, the ATY 105 is then taken up from the delivery unit104 by a take up unit 106, similar to the step S106 described above.

In the present disclosure, an air textured yarn (ATY) is disclosed. Insome embodiments, the ATY 105 is manufactured by the air texturingmachine 100 as described above or illustrated in FIG. 1. In someembodiments, the ATY 105 is manufactured by the method S100 as describedabove or illustrated in FIG. 2 or the method S200 as described above orillustrated in FIG. 3. FIG. 4 is a microscopic image showing across-sectional view of the ATY 105 according to one embodiment of thepresent disclosure.

In some embodiments, the ATY 105 includes at least two filaments withdifferent cross-sectional shapes. In some embodiments, the ATY 105includes the first filament 105 a and the second filament 105 b. In someembodiments, the first filament 105 a and the second filament 105 b areuniformly distributed in the ATY 105. In other words, the first filament105 a and the second filament 105 b are uniformly mixed with each other.

In some embodiments, the first filament 105 a has a first cross section,and the second filament 105 b has a second cross section. In someembodiments, the first cross section of the first filament 105 a isdifferent from the second cross section of the second filament 105 b. Insome embodiments, the first cross section has a substantially circularshape and has an M ratio substantially equal to or less than 1.3. Insome embodiments, the second cross section has a polygonal shapeincluding 3 to 6 lobes. In some embodiments, the second cross sectionhas the polygonal shape including 5 or 6 lobes. In some embodiments, thesecond cross section is a tri-lobe shape, a four-lobe shape, a star, apentagram, a hexagram, a heptagram, an octagram or the like.

In some embodiments as shown in FIG. 4, the first cross section of thefirst filament 105 a has a substantially circular shape, and the secondcross section of the second filament 105 b is a polygonal shapeincluding 5 lobes. In some embodiments, the first cross section of thefirst filament 105 a is free of a lobe and a recess. In someembodiments, the second cross section includes several lobes protrudingfrom a central portion of the second filament 105 b, and severalrecesses between the lobes. In some embodiments, each of the recesses isdisposed between two adjacent lobes. In some embodiments, the ATY 105includes a void 105 g surrounded by the first filament 105 a and thesecond filament 105 b.

In some embodiments as shown in FIG. 4, at least a portion of the firstfilament 105 a is disposed between two adjacent lobes of the secondfilament 105 b. In some embodiments, two adjacent second filaments 105 bare interlocked with each other. In some embodiments, one of the lobesof the second filament 105 b is disposed between two adjacent lobes ofanother second filament 105 b.

FIGS. 5 to 8 illustrate various schematic cross-sectional views of thesecond filament 105 b according to embodiments of the presentdisclosure. In some embodiments as shown in FIG. 5, the second crosssection has the polygonal shape including 3 lobes. In some embodimentsas shown in FIG. 6, the second cross section has the polygonal shapeincluding 4 lobes. In some embodiments as shown in FIG. 7, the secondcross section has the polygonal shape including 5 lobes. In someembodiments as shown in FIG. 8, the second cross section has thepolygonal shape including 6 lobes.

In some embodiments, as shown in FIGS. 5 to 8, the second cross sectionincludes several lobes 105 e protruding from the central portion of thesecond filament 105 b, and several recesses 105 f between the lobes 105e. In some embodiments, each of the recesses 105 f is disposed betweentwo adjacent lobes 105 e.

In some embodiments, the second cross section of the second filament 105b has a major axis with a first length D and a minor axis with a secondlength d. In some embodiments, the first length D is a longest diameterof the second cross section, and the second length d is a shortestdiameter of the second cross section. In some embodiments, the centralportion of the second filament 105 b has the second length d. In someembodiments, the second cross section of the second filament 105 b canbe measured at predetermined magnifications when using a microscope, anda ratio of the first length D to the second length d can then becalculated. In some embodiments, the ratio D:d is defined as a degree ofmodification, which is also referred to as an M ratio. In someembodiments, the second filament 105 b has an M ratio (D:d)substantially greater than 1.5. In some embodiments, the M ratio of thesecond filament 105 b is substantially greater than 2. In someembodiments, the M ratio of the second filament 105 b is in a range ofabout 1.6 to about 3. In some embodiments, as shown in FIGS. 5 to 8, thesecond filament 105 b has the M ratio (D:d) substantially greater than1.5.

FIGS. 9 to 11 illustrate various schematic cross-sectional views of thefirst filament 105 a according to embodiments of the present disclosure.In some embodiments, the first cross section has a substantiallycircular shape and has the M ratios (D′:d′) less than or substantiallyequal to 1.5. The M ratios of the first cross sections of the firstfilament 105 a as shown in FIGS. 9 to 11, are 1.3, 1.2 and 1.1,respectively. In some embodiments, the first cross section of the firstfilament 105 a is a circular shape. In some embodiments, the M ratio ofthe first cross section of the first filament 105 a is substantiallyequal to 1.

Referring back to FIG. 4, the ATY 105 includes the first filament 105 aand the second filament 105 b having cross-sectional profiles differentfrom each other. Because the different cross-sectional profiles createdifferent aerodynamic effects during the air texturizing process, theATY 105 having loops with desired dimension, density and distributioncan be produced.

In some embodiments, the ATY 105 includes the first filament 105 a, thesecond filament 105 b and a third filament (not shown) havingcross-sectional profiles different from each other. In some embodiments,the third filament disposed adjacent to the first filament 105 a and thesecond filament 105 b, and has a third cross section. In someembodiments, the third cross section is different from the second crosssection and has a polygonal shape including 3 to 6 lobes. In someembodiments, the configuration of the third cross section of the thirdfilament is shown in FIGS. 5 to 8. In some embodiments, the void 105 gis surrounded by at least one of the first filament 105 a, the secondfilament 105 b and the third filament. In some embodiments, the void 105g is adjacent to the third filament. In some embodiments, the loop isformed by the third filament.

FIG. 12 illustrates microscopic images of a side view of the ATY 105produced by the air texturing machine 100 described above or illustratedin FIG. 1, the manufacturing method S100 described above or illustratedin FIG. 2, or the manufacturing method S200 described above orillustrated in FIG. 3. In some embodiments, as shown in FIG. 12, the ATY105 has small, dense and uniform loops, and therefore the ATY 105 loopscan offer a desirable fluffy, comfortable or cotton-like feeling andwill not be easily snagged.

In some embodiments, the loop protruding from the ATY 105 has a height Hof less than 480 μm. In some embodiments, the height H of the loop is ina range of about 150 μm to about 480 μm. In some embodiments, the heightH of the loop is in a range of about 100 μm to about 280 μm.

In contrast, loops of comparative example yarn 205 produced by othertexturing machine or other texturing method are larger, less dense andless uniform compared to the loops of the ATY 105. The comparativeexample yarn 205 has larger and longer loops and thus can be easilysnagged.

In the present disclosure, a fabric, garment or clothing made of the ATY105 is disclosed. FIG. 13 illustrates a fabric 300 made of the ATY 105as described above or illustrated in FIG. 4 according to one embodimentof the present disclosure, as well as a comparative example fabric 301made of other yarns. In some embodiments, the fabric 300 has a lowsee-through effect. As shown in FIG. 13, the fabric 300 has a lowersee-through effect than the comparative example fabric 301. In otherwords, an object behind the fabric 300 cannot be clearly seen, while theobject behind the comparative example fabric 301 can be clearly seen.

In conclusion, the ATY of the present disclosure includes a firstfilament and a second filament having a length difference substantiallyequal to or less than 4%. Further, the first filament and the secondfilament are fed into a nozzle unit at a same or approximately samefeeding speed, and then texturized by the nozzle unit, such that thefirst filament and the second filament can have substantially equallengths. The substantially equal lengths of the first filament and thesecond filament can prevent the ATY from being easily snagged. The firstfilament and the second filament have different M ratios. For example,the first filament has a substantially circular cross section and has anM ratio substantially equal to or less than 1.3, and the second filamenthas a polygonal cross section. The M ratio of the second filament may begreater than 1.5. The cross section of the second filament is differentfrom the first cross section and has a polygonal shape including 3 to 6lobes. The first filament and the second filament have differentcross-sectional profiles with different aerodynamic effects, and thusthe ATY formed by the first filament and the second filament have small,dense and uniform loops to achieve desired properties such as fluffyfeeling and non-see-through effect.

Although the present disclosure and its advantages have been describedin detail, it should be understood that various changes, substitutionsand alterations can be made herein without departing from the spirit andscope of the disclosure as defined by the appended claims. For example,many of the processes discussed above can be implemented in differentmethodologies and replaced by other processes, or a combination thereof.

Moreover, the scope of the present application is not intended to belimited to the particular embodiments of the process, machine,manufacture, composition of matter, means, methods and steps describedin the specification. As one of ordinary skill in the art will readilyappreciate from the present disclosure, processes, machines,manufacture, compositions of matter, means, methods or steps, presentlyexisting or later to be developed, that perform substantially the samefunction or achieve substantially the same result as the correspondingembodiments described herein, may be utilized according to the presentdisclosure. Accordingly, the appended claims are intended to includewithin their scope such processes, machines, manufacture, compositionsof matter, means, methods and steps.

What is claimed is:
 1. An air textured yarn (ATY), comprising: a firstfilament having a first cross section; and a second filament disposedadjacent to the first filament and having a second cross section,wherein the first cross section has a substantially circular shape andhas a degree of modification (M ratio) less than or substantially equalto 1.3, the second cross section different from the first cross sectionhas a polygonal shape including 3 to 6 lobes, and a difference between alength of the first filament and a length of the second filament is lessthan or substantially equal to 4%.
 2. The ATY of claim 1, wherein thelength of the first filament is substantially equal to the length of thesecond filament.
 3. The ATY of claim 1, wherein the second cross sectionhas an M ratio greater than 1.5.
 4. The ATY of claim 3, wherein the Mratio of the second cross section is in a range of about 1.6 to about 3.5. The ATY of claim 1, wherein the second cross section has thepolygonal shape including 5 or 6 lobes.
 6. The ATY of claim 1, furthercomprising: a third filament disposed adjacent to the first filament andthe second filament and having a third cross section, wherein the thirdcross section is different from the first cross section of the firstfilament and the second cross section of the second filament.
 7. The ATYof claim 1, further comprising: a loop formed by the first filament orthe second filament, wherein a height of the loop is less than 480 μm.8. A fabric comprising the ATY as claimed in claim
 1. 9. A method ofmanufacturing an ATY, comprising: extruding a first filament and asecond filament from a yarn magazine; feeding the first filament into anozzle unit by a first feeding member of a feeding unit at a firstfeeding speed; feeding the second filament into the nozzle unit by asecond feeding member of the feeding unit at a second feeding speed;blowing the first filament and the second filament by a flow in thenozzle unit to form the ATY including the first filament and the secondfilament; pulling the ATY out from the nozzle unit by a delivery unit;and taking up the ATY from the delivery unit by a take up unit, whereina difference between the first feeding speed and the second feedingspeed is less than or substantially equal to 4%, a first cross sectionof the first filament and a second cross section of the second filamenthave different cross-sectional shapes, the first cross section of thefirst filament has a substantially circular shape and has a degree ofmodification (M ratio) less than or substantially equal to 1.3, and thesecond cross section of the second filament has a polygonal shapeincluding 5 or 6 lobes and has an M ratio substantially greater than1.5.
 10. The method of claim 9, wherein the first feeding speed issubstantially equal to the second feeding speed.
 11. The method of claim9, further comprising: feeding a polymeric material into a spinneret;forming the first filament and the second filament from the polymericmaterial; outputting the first filament and the second filament from thespinneret; combining the first filament and the second filament to forma yarn; and conveying the yarn including the first filament and thesecond filament to the yarn magazine.
 12. The method of claim 11,further comprising: feeding a polymeric material into a first spinneretand a second spinneret; forming the first filament and the secondfilament from the polymeric material; outputting the first filament fromthe first spinneret and the second filament from the second spinneret;combining the first filament and the second filament to form a yarn; andconveying the yarn including the first filament and the second filamentto the yarn magazine.